Nested Female Terminal Contacts for Higher Current and Thermal Balance

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Solution Overview

Problem

Existing electrical battery systems face challenges in increasing the current-carrying capacity and improving thermal balance in the electrical contact between female and male connection devices.

Innovation Solution

A female connector device with nested outer and inner contact bodies, featuring spring leg regions and gaps, made of copper alloy or coated with tin-silver, designed to enhance electrical contact points and thermal balance through elastic spring behavior and precise contact surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a single contact body is used in the female connector device, then the device complexity is reduced, but the current-carrying capacity and number of electrical contact points are insufficient

Engineering Contradiction:

Improvenumber of electrical contact pointsVSAvoidcontact body structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent implements a nested contact body structure where an inner contact body is positioned within an outer contact body. The inner contact body has inner spring leg regions that contact the male connector, while the outer contact body has outer spring leg regions that also contact the male connector. This nesting arrangement multiplies the number of electrical contact points without proportionally increasing device complexity, as both contact bodies share the same basic structural layout and mounting mechanism.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The contact body is segmented into functionally distinct inner and outer contact bodies, each with their own spring leg regions. The inner contact body handles specific electrical contacts while the outer contact body handles other electrical contacts, allowing the current to be distributed across multiple separate contact paths. This segmentation increases the total current-carrying capacity and number of contact points while maintaining manageable complexity through modular design.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the spring leg regions contact the male connection device at the back region, then the structural support is improved, but the electrical contact resistance increases and thermal balance deteriorates

Engineering Contradiction:

Improveelectrical contact qualityVSAvoidthermal balance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent extracts the electrical contact function from the back region structure by positioning spring leg regions that protrude from the back region toward the male connector. The actual electrical contacts occur at these extended spring leg regions rather than at the back region itself, separating the structural support function (handled by the back region) from the electrical contact function (handled by the spring leg regions). This extraction reduces electrical contact resistance and improves thermal balance by creating dedicated contact zones away from the bulk material.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a high number of electrical contact points and improved thermal balance, enhancing the current-carrying capacity and reducing insertion forces while maintaining a robust and precise electrical connection.

Implementation Method 1

The outer spring leg regions are designed to electrically contact the received male connection device... The inner spring leg regions are designed to electrically contact the received male connection device

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

made of copper alloy or coated with tin-silver, designed to enhance electrical contact points and thermal balance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

The provision of two contact bodies can promote a thermal balance in the female connection device, particularly in a contact system of the battery system comprising the female connection device and the male connection device

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4636958A1Female terminal device, battery system, electric battery pack, and electric battery device

Publication Date: 2025.10.22 ANDREAS STIHL AG & CO KG

Figure 1~2
Figure 3~5

AI summary

The invention relates to a female connection device (1) for receiving a male connection device (51), comprising: an outer contact body (2) having an outer back region (3) and two outer spring leg regions (4) projecting opposite one another from the outer back region (3), wherein the outer spring leg regions (4) are designed to electrically contact the male connection device (51) at a distance from the outer back region (3), wherein the outer back region (3) and the outer spring leg regions (4) together form an outer body section (5) of the outer contact body (2), and an inner contact body (6) having an inner back region (7) and two inner spring leg regions (8) projecting opposite one another from the inner back region (7), wherein the inner spring leg regions (8) are designedto electrically contact the male connection device (51) at a distance from the inner back region (7), wherein the inner back region (7) and the inner spring leg regions (8) together form an inner body section (9) of the inner contact body (6), wherein the outer body section (5) and the inner body section (9) are arranged in a nested manner such that they are not in contact with one another or that they are only in contact with one another at the inner back region (7) and at the outer back region (3).